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Abstract:

An approach for producing a tolerance-corrected actuator for a
supercharging device may include connecting a connecting element to a
regulating rod of a regulating component assembly, bringing a
tolerance-corrected actuator into a predefined position in response to a
defined signal and adjusting a predetermined overall length of the
regulating component assembly by shifting the connecting element relative
to the regulating rod.

Claims:

1. A method for producing a tolerance-corrected actuator for a
supercharging device comprising: connecting a connecting element to a
regulating rod of a regulating component assembly, bringing a
tolerance-corrected actuator into a predefined position in response to a
defined signal, adjusting a predetermined overall length of the
regulating component assembly by shifting the connecting element relative
to the regulating rod and wherein the connecting element is connected to
the regulating rod in a fixed manner.

2. The method according to claim 1, further comprising pushing a
connecting plate into a groove of the regulating rod for adjusting the
overall length of the connecting element.

3. An actuator on a supercharging device, comprising: a regulating
component assembly configured to transmit at least translatory movements,
wherein a length of the regulating component assembly at a predefined
position of the actuator has a predetermined overall length, wherein the
actuator with respect to the overall length is tolerance-corrected and
two actuators of the same type have the same overall length.

4. The actuator according to claim 3, wherein the regulating component
assembly includes a regulating rod and a connecting element connected to
the regulating rod.

5. The actuator according to claim 4, wherein the connecting element
includes a connecting plate and a connecting contour.

6. The actuator according to claim 5, wherein the connecting plate is at
least partially pushed into a groove of the regulating rod.

7. The actuator according to claim 5, wherein the overall length of the
regulating component assembly is defined as a distance from the
connecting contour to a connecting flange of the actuator, wherein the
actuator is connected to the supercharging device via the connecting
flange.

8. The actuator according to claim 5, wherein the connecting contour is
designed as at least one of a pin and a stud, and is at least
rotation-movably positioned in a recess of an adjusting lever of at least
one of a variable turbine geometry and of a wastegate valve by a fixing
element.

9. A method for attaching an actuator to a supercharging device,
comprising: positioning the actuator relative to the supercharging
device, bringing at least one of a variable turbine geometry and a
wastegate valve of the supercharging device into a predefined position,
bringing the actuator into a predefined position, connecting an adjusting
lever to a regulating component assembly of the actuator; and connecting
an actuating element of the at least one of the variable turbine geometry
and the wastegate valve to the adjustment lever.

10. The method according to claim 9, further comprising introducing the
actuating element designed as at least one of a spindle and stud into a
further recess of the adjusting lever.

11. (canceled)

12. The actuator according to claim 6, wherein the overall length of the
regulating component assembly is defined as a distance from the
connecting contour to a connecting flange of the actuator, wherein the
actuator is connected to the supercharging device via the connecting
flange.

13. The actuator according to claim 12, wherein the connecting contour is
designed as at least one of a pin and stud and is at least rotationally
and movably positioned in a recess of an adjusting lever of at least one
of a variable turbine geometry and of a wastegate valve by a fixing
element.

14. The actuator according to claim 6, wherein the connecting contour is
designed as at least one of a pin and a stud and is at least rotationally
and movably positioned in a recess of an adjusting lever of at least one
of a variable turbine geometry and of a wastegate valve by a fixing
element.

Description:

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims priority to German Patent Application DE 10
2010 040 583.3 filed Sep. 10, 2010, and International Patent Application
PCT/EP2011/064814, filed Aug. 29, 2011, both of which are hereby
incorporated by reference in their entirety.

TECHNICAL FIELD

[0002] The present invention relates to a method for producing a
tolerance-corrected actuator for a supercharging device, in particular
for an exhaust-gas turbocharger of a motor vehicle. Furthermore, the
invention likewise relates to a supercharging device, in particular an
exhaust-gas turbocharger of a motor vehicle and an associated method for
attaching an actuator to such a supercharging device.

BACKGROUND

[0003] From DE 10 2008 045 227 A1 a method for the simplified attachment
of an actuator designed as a pressure can to an exhaust-gas turbocharger
is known. For offsetting tolerances on the part of the exhaust-gas
turbocharger and on the part of the pressure can, an adjusting lever of a
variable turbine geometry or of a wastegate valve is brought into a
predefined position. This can, for example, be the position of the closed
wastegate valve. Following this, the distance between a predefined
attachment position of the pressure can and the adjusting lever is
measured. Following this, the pressure can is likewise brought into a
predefined position and the actuator rod of the actuator marked at one
point. Here, the distance of this marked point to the attachment flange
of the actuator on the exhaust-gas turbocharger corresponds to the length
which was previously measured between the predefined attachment position
of the actuator and the adjusting lever. Following this, the actuator is
connected to the exhaust-gas turbocharger by means of the attachment
flange and the actuator rod at the marked point connected to the
adjusting lever. Through such an attachment method of an actuator to an
exhaust-gas turbocharger, both the tolerances of the exhaust-gas
turbocharger, in particular in the region of the wastegate valve or of
the variable turbine geometry, as well as the tolerances of the actuator
or of the pressure can, can be compensated.

[0004] Thus, through such a method, a tolerance offset of the assembly and
production tolerances of an actuator and of a charging device can be
carried out simultaneously. Usually, interface parts of the actuator
and/or of the supercharging device are connected to one another during
the assembly of the supercharging device in particular through
welding-on.

[0005] Disadvantageous in such an assembly method of a supercharging
device is the major effort involved during maintenance work if the
actuator is to be exchanged. Here, the tolerances of the actuator can be
so large that a simple replacement of the actuator is not possible,
wherein a maintenance method that is similar to the assembly method of
the supercharging device has to be carried out so that when replacing the
actuator and the assembly and production tolerances of the new actuator
and of the old supercharging device are taken into consideration. To the
end customer or in a warranty case to a manufacturer of the supercharging
device, this can involve high costs.

SUMMARY

[0006] Accordingly, the present invention deals with the problem of
stating an improved or at least an alternative embodiment for an actuator
of a supercharging device, in particular of an exhaust-gas turbocharger
in a motor vehicle, and for an associated production method and for a
supercharging device, in particular for an exhaust-gas turbocharger of a
motor vehicle and an associated attachment method of an actuator to such
a supercharging device, which is characterized in particular through a
simplified exchange of the actuator.

[0007] According to the invention, this problem is solved through the
subjects of the independent claims. Advantageous embodiments are subject
of the dependent claims.

[0008] With a method for producing a tolerance-corrected actuator for a
supercharging device, in particular for an exhaust-gas turbocharger of a
motor vehicle, wherein the actuator comprises a regulating component
assembly, comprising a control rod and a connecting element that can be
connected to the control rod, the invention is based on the general idea
of bringing the actuator into a predefined position and to adjust a
predetermined overall length of the control component by shifting the
connecting element relative to the control rod and then connect the
connecting element to the control rod. Through such a method, a
predefined overall length of the regulating component assembly can be
realised with respect to a predefined position of the actuator by
shifting the connecting element relative to the control rod. Because of
this, such a tolerance-corrected actuator can be advantageously produced.
Since in this case with respect to a predefined position of the actuator
the overall length of the regulating component assembly assumes a
predefined length, the position tolerances of the actuator with such an
actuator provided with a pre-adjusted length are compensated, which means
that each actuator of the same type, which in a predefined position has a
predetermined length, has negligible tolerances due to the position.
Thus, when such an actuator is being exchanged, no tolerance correction
has to be carried out. For example during maintenance, such a
tolerance-corrected actuator can consequently be exchanged without
elaborate tolerance correction. This reduces the cost to the end customer
and if applicable in a warranty case also to the manufacturer of the
supercharging device. Here, actuator of the same time is to mean
actuators having the same specifications.

[0009] A further general idea of the invention is designing an actuator
for a supercharging device, in particular for an exhaust-gas turbocharger
of a motor vehicle in such a manner that the actuator comprises a
regulating component assembly, by means of which at least translatory
movements can be transmitted, wherein the overall length of the
regulating component assembly in a predefined position of the actuator
has a predetermined length.

[0010] A further general idea of the invention is a method for the
attachment of an actuator to a supercharging device, in particular to an
exhaust-gas turbocharger of a motor vehicle, wherein the actuator is
positioned and fixed relative to the supercharging device, with which a
variable turbine geometry or a wastegate valve of the supercharging
device is brought into a predefined position, with which the actuator is
brought into a predefined position, with which an adjusting lever
rotation-movably connected to a regulating component assembly of the
actuator is rotation-rigidly connected to an actuating element of the
variable turbine geometry or of the wastegate valve. Since with such a
method for the attachment of an actuator a tolerance-corrected actuator
is being used, merely the assembly and production tolerances of the
supercharging device have to be compensated upon the assembly of the
actuator with the supercharging device during the attachment process.

[0011] Further important features and advantages of the invention are
obtained from the subclaims, from the drawings and from the associated
Figure description by means of the drawings.

[0012] It is to be understood that the features mentioned above and still
to be explained in the following cannot only be used in the respective
combination stated but also in other combinations or by themselves
without leaving the scope of the present invention.

[0013] Preferred exemplary embodiments of the invention are shown in the
drawings and are explained in more detail in the following description,
wherein same reference characters relate to same or similar or
functionally same components.

[0019]FIG. 5 the actuator positioned in a welding position in
installation position with the supercharging device.

DETAILED DESCRIPTION

[0020]FIG. 1 shows an actuator 1 prior to the final assembly. The
actuator 1 in this case comprises a regulating rod 2 and a connecting
element 3. In the connected state, the regulating rod 2 and the
connecting element 3 together form a regulating component assembly 4.
Furthermore, the actuator 1 comprises a connecting flange 5, with which
the actuator 1 can be connected to a supercharging device 6 shown in the
FIG. 3. Here, the connecting element 3 is constructed of a connecting
plate 7 and a connecting contour 8. The connecting contour 8 can be
designed as pin or stud, which can be positioned in a recess 9 of an
adjusting lever 10, and by means of a fixing element 11 can be fixed at
least rotation-movably to the adjusting lever 10. Here, the fixing
element 11 can be designed as locking rim, which following positioning of
the connecting contour 8 in the recess 9 is pushed onto the latter.

[0021] Furthermore, the regulating rod 2 is equipped with a groove 12,
into which the connecting plate 7 of the connecting element 3 can be
pushed. By shifting the connecting plate 7 in the groove 12 along a
longitudinal axis 13 of the regulating rod 2, an overall length L of the
regulating component assembly 4 can be changed by the offsetting length
N. Here, the overall length L can be determined as distance between the
connecting flange 5 and a centre axis 14 of the connecting contour 8
designed as pin or stud. For forming a tolerance-corrected actuator 1,
the overall length L is adjusted after the actuator 1 has been brought
into a predefined position, by shifting the connecting plate 7 in the
groove 12 along the longitudinal axis 13.

[0022] Here, a predefined position of the actuator 1 can be a defined
position of the gearing and/or a defined position of the position sensor
and/or a defined position of the regulating rod 2. Such a predefined
position of the actuator 1 can be adjusted through a signal with which
the actuator is supplied or can be detected by means of a signal for
example of a sensor. Following the alignment of the connecting plate 7 in
the groove 12, the regulating rod 2 is connected to the connecting plate
7 in the region of the groove 12. The connecting can be carried out
through screwing, gluing, welding, riveting, crimping or the like.
Following the final fixing of the connecting plate 7 to the regulating
rod 2, such a tolerance-corrected actuator 1 has a predetermined overall
length L with respect to a predefined position of the actuator. A
completed, tolerance-corrected actuator 1 is shown in FIG. 2.

[0023]FIG. 3 shows the actuator 1 in installation position with the
supercharging device 6. Here, the actuator 1 is tolerance-corrected
according to the method described before and connected to the adjusting
lever 10, for example as described before. Here, the adjusting lever 10
is connected to the regulating component assembly 4 rotation-movably
relative to the connecting contour 8. A further recess 15 of the
adjusting lever 10 is positioned above an opening 16 of the supercharging
device 6, wherein the opening 16 is designed for receiving an actuating
element 17.

[0024] According to FIG. 4, such an actuating element 17 can be designed
as spindle or stud, which for example in the case of a wastegate valve,
is rotation-rigidly connected to a flap 18 of the wastegate valve. For
aligning, the actuating element 17 is now pushed into the opening 16 and
the flap 18 of the wastegate valve brought into a predefined position.
Here, the predefined position can be the position of the closed wastegate
valve.

[0025] As is shown in FIG. 5, the actuating element 17 is then arranged in
the further recess 15 of the adjusting lever 10. Following positioning of
the actuating element 17 in the further recess 15, the
tolerance-corrected actuator 1 is brought into a centre position 19 and
slowly moved into a connecting position 20 in order to take play out of
the system. Here, during this movement of the actuator 1, the variable
turbine geometry or the wastegate valve is fixed in the respective
predefined position. On reaching the connecting position 20, the
actuating element 17 is connected to the adjusting lever 10 at the
connecting point 21. Preferably, the connecting point 21 is designed as
welding point.

[0026] Accordingly, the production or assembly tolerances of the actuator
1 and of the supercharging device 6 are compensated insofar that they are
negligible. Since the actuator 1 is now connected to the adjusting lever
10 via the connecting contour 8 of the connecting element 3 by means of a
fixing element 11, the actuator 1 can be separated from the adjusting
lever 10 by disconnecting the fixing element 11. Following the
disconnection of the connecting flange 5, the actuator 1 can be
completely separated from the supercharging device 6. Since the actuator
1 is embodied in a tolerance-corrected manner, it can thus be quickly
exchanged and following connecting of the new exchanged actuator 1 by
means of the fixing element 11 to the adjusting lever 10, the function of
the supercharging device 6 in interaction with the actuator 1 is
re-established as before.

[0027] Preferably, an electric actuator is used as actuator 1 and
particularly preferably an electric wastegate adjustor.

[0028] Following the completed assembly of the actuator 1 to the
supercharging device 6 and after the connecting of the connecting element
17 to the adjusting lever 10 and, both the adjusting valve of the
actuator with a closed wastegate valve or a closed variable turbine
geometry as well as the concentricity of the regulating rod can be
measured. Here, the measuring can take place on a coordinate measuring
machine.

[0029] In the case of the welding of the actuating element 17 to the
adjusting lever 10, the welding point can be preheated to
500+/-100° C. by means of a laser and then the welding of the
actuating element 17 to the adjusting lever 10 carried out by means of a
solid state laser.